Table of Contents 7- i

Section 7

HVAC
CONTENTS
Precautions .................................................7-1
Precautions............................................................. 7-1 Precautions on HVAC ........................................... 7-1 A/C System Symptom Diagnosis ........................7B-7 Abnormal Noise Symptom Diagnosis of A/C System ..............................................................7B-9 A/C System Performance Inspection ................7B-10 A/C System Inspection at ECM.........................7B-15 Repair Instructions ............................................7B-17 Operation Procedure for Refrigerant Charge ....7B-17 Condenser Assembly On-Vehicle Inspection........................................................7B-22 Condenser Assembly Removal and Installation .......................................................7B-22 Desiccant Removal and Installation ..................7B-23 HVAC Unit Components ...................................7B-24 HVAC Unit Removal and Installation ................7B-25 Evaporator Inspection .......................................7B-25 Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation .......................................................7B-25 Evaporator Thermistor (Evaporator Temperature Sensor) Inspection.....................7B-26 Expansion Valve Removal and Installation .......7B-26 Expansion Valve Inspection ..............................7B-27 A/C Refrigerant Pressure Sensor and Its Circuit Inspection.............................................7B-27 A/C Refrigerant Pressure Sensor Removal and Installation ................................................7B-27 A/C Switch Inspection .......................................7B-27 Compressor Relay Inspection ...........................7B-28 Compressor Drive Belt Inspection and Adjustment ......................................................7B-28 Compressor Drive Belt Removal and Installation .......................................................7B-29 Compressor Assembly Removal and Installation .......................................................7B-29 Compressor Assembly Components.................7B-30 Magnet Clutch Inspection..................................7B-30 Magnet Clutch Removal and Installation...........7B-30 Relief Valve Inspection......................................7B-32 Relief Valve Removal and Installation...............7B-32 Specifications .....................................................7B-33 Tightening Torque Specifications......................7B-33 Special Tools and Equipment ...........................7B-34 Recommended Service Material .......................7B-34 Special Tool ......................................................7B-34

Heater and Ventilation............................. 7A-1

General Description .............................................7A-1 Heater and Ventilation Construction ................... 7A-1 Schematic and Routing Diagram........................7A-2 Heater and Ventilation Wiring Circuit Diagram ............................................................ 7A-2 Diagnostic Information and Procedures............7A-3 Heater and Ventilation Symptom Diagnosis........ 7A-3 Repair Instructions ..............................................7A-4 HVAC Unit Components ..................................... 7A-4 HVAC Unit Removal and Installation .................. 7A-5 Blower Motor Removal and Installation............... 7A-5 Blower Motor Inspection ..................................... 7A-5 Blower Motor Resistor Removal and Installation ......................................................... 7A-6 Blower Motor Resistor Inspection ....................... 7A-6 HVAC Control Unit Components......................... 7A-7 HVAC Control Unit Removal and Installation ......................................................... 7A-7 Blower Speed Selector Inspection ...................... 7A-8 Air Intake Switch Inspection ................................ 7A-9 Air Intake Control Actuator Removal and Installation ......................................................... 7A-9 Air Intake Control Actuator Inspection ................ 7A-9 Center Ventilation Louver Removal and Installation ....................................................... 7A-10 Side Ventilation Louver Removal and Installation ....................................................... 7A-10 Air Filter Removal and Installation .................... 7A-11 Air Filter Cleaning ............................................. 7A-11

Air Conditioning System......................... 7B-1

Precautions...........................................................7B-1 A/C System Caution............................................ 7B-1 Precautions on Servicing A/C System ................ 7B-1 General Description .............................................7B-3 Refrigerant Type Construction ............................ 7B-3 Sub-Cool A/C System Description ...................... 7B-3 Schematic and Routing Diagram........................7B-5 Major Components of A/C System...................... 7B-5 A/C System Wiring Diagram ............................... 7B-6 Diagnostic Information and Procedures............7B-7

7-1 Precautions:

Precautions
Precautions
Precautions on HVAC
S4RS0A7000001

Air Bag Warning Refer to Air Bag Warning: in Section 00. A/C System Caution Refer to A/C System Caution: in Section 7B. Precautions on Servicing A/C System Refer to Precautions on Servicing A/C System: in Section 7B.

Heater and Ventilation:

7A-1

Heater and Ventilation

General Description
Heater and Ventilation Construction
S4RS0A7101001

I4RS0A710001-

1. HVAC unit 2. Ventilator duct 3. Defroster nozzle 4. Heater core 5. Side ventilation air

6. Foot air 7. Front defroster air 8. Side defroster air 9. Fresh air 10. Recirculation air

11. Center ventilation air 12. Air intake door 13. Blower motor 14. Resistance board

7A-2 Heater and Ventilation:

Schematic and Routing Diagram

Heater and Ventilation Wiring Circuit Diagram
S4RS0A7102001

7 10A 10A 10A 1 4 5 RED/BLK BLK/YEL BLK

2 M BLK/WHT YEL BLU/WHT RED 6 RED/BLK M 10 RED GRN BRN 8 BLK/RED RED/YEL BLK G18-13 G18-9 G18-10 G18-8 G18-7 G18-4 G18-3 BLK/ORN G18-14 G19-6 G19-7 G19-3 G19-2 G19-1 BLK 3

80A

9 12V BLU/WHT E23-19

I4RS0A710002-

1. Ignition switch 2. Blower motor 3. HVAC control unit

4. Lighting switch 5. Blower motor relay 6. Blower motor resistor

7. Junction block assembly 8. BCM 9. ECM

10. Air intake control actuator

Heater and Ventilation:

7A-3

Diagnostic Information and Procedures

Heater and Ventilation Symptom Diagnosis
S4RS0A7104001

Condition Blower motor does not operate with blower speed selector ON.

Possible cause Fuse blown Blower motor resistor faulty Blower speed selector faulty Blower motor faulty Wiring or grounding faulty Temperature control cable broken or bent Temperature control lever faulty Incorrect installation of temperature control cable Temperature control door assembly broken Air ducts clogged Heater core leaked or clogged Heater hoses leaked or clogged Thermostat faulty Airflow control cable broken or bent Airflow control lever faulty Incorrect installation of temperature control cable Airflow control door assembly broken Air ducts leaked or clogged Air intake door broken Air intake control actuator faulty Air intake switch faulty Wiring or grounding faulty

Incorrect temperature output

Correction / Reference Item Check related fuses, and then check for short circuit to ground. Check blower motor resistor referring to Blower Motor Resistor Inspection: . Check blower speed selector referring to Blower Speed Selector Inspection: . Check blower motor referring to Blower Motor Inspection: . Repair as necessary. Check temperature control cable. Check temperature control lever. Check position and adjust it as necessary. Repair temperature control door assembly. Repair air ducts. Replace heater core. Replace heater hoses. Check thermostat referring to Thermostat Inspection: in Section 1F. Check airflow control cable. Check airflow control lever. Check position and adjust it as necessary. Repair airflow control door assembly. Repair air ducts. Repair air intake door. Check air intake control actuator referring to Air Intake Control Actuator Inspection: . Check air intake switch referring to Air Intake Switch Inspection: . Repair as necessary.

Air outlet port does not change or does not agree with airflow selectors position even if airflow selector is changed. Air intake door does not change even if air intake mode is changed.

7A-4 Heater and Ventilation:

Repair Instructions
HVAC Unit Components
S4RS0A7106001

2 4

17 18 5 7

6 8 7

5 15 15 15

2 14 8 9

19 10 14

11 13

17

16

12

I4RS0A710003-

1. Fresh air inlet duct 2. Blower upper case 3. Air intake control actuator 4. Air filter 5. Heater unit upper case

6. Foot duct 7. Airflow control door assembly 8. Temperature control door assembly 9. Blower motor resistor 10. Blower lower case

11. Blower motor 12. Heater unit lower case 13. Heater core 14. Temperature control lever 15. Airflow control lever

16. Drain hose 17. Packing 18. Filter cover 19. Cable lock clamp

Heater and Ventilation:

7A-5

HVAC Unit Removal and Installation

S4RS0A7106002

Removal 1) Disconnect negative () cable from battery. 2) Disable air bag system referring to Disabling Air Bag System: in Section 8B. 3) Remove cowl top panel from vehicle body referring to Cowl Top Components: in Section 9K. 4) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2). 5) Remove instrument panel from vehicle body referring to Instrument Panel Removal and Installation: in Section 9C. 6) Remove nuts (3). 7) Remove HVAC unit from vehicle body.

1 2 3
I4RS0A710005-

Installation Reverse removal procedure noting the following instruction. Enable air bag system referring to Enabling Air Bag System: in Section 8B.

3 2 3

Blower Motor Inspection

S4RS0A7106004

Check for continuity between two terminals as shown. If there is no continuity, replace blower motor.

3
I4RS0A710004-

Installation Reverse removal procedure noting the following instructions. Be careful not to catch any cable and wiring harness in inappropriate position. Adjust control cables of HVAC control unit referring to HVAC Control Unit Removal and Installation: . Fill engine coolant to radiator. Enable air bag system referring to Enabling Air Bag System: in Section 8B.

I4RS0A710006-

Check for operation and current. a. Put blower motor (1) in a soft-jawed vise. b. Connect battery to blower motor as shown. c. Check if blower motor operates smoothly without noise. d. Check if ammeter indicates the specified current. If measured current is out of specification, replace blower motor. Blower motor specified current at 12 V 16 A maximum

Blower Motor Removal and Installation

S4RS0A7106003

Removal 1) Disconnect negative () cable from battery. 2) Disable air bag system referring to Disabling Air Bag System: in Section 8B. 3) Disconnect connector (1) from blower motor (2). 4) Remove blower motor from HVAC unit by removing screws (3).

I4RS0A710007-

7A-6 Heater and Ventilation:

Blower Motor Resistor Removal and Installation

S4RS0A7106005

Removal 1) Disconnect negative () cable from battery. 2) Disable air bag system referring to Disabling Air Bag System: in Section 8B. 3) Remove glove box from instrument panel. 4) Remove passenger air bag module from instrument panel referring to Passenger Air Bag (Inflator) Module Removal and Installation: in Section 8B. 5) Remove bolts (1) from instrument panel.

Installation Reverse removal procedure noting the following instruction. Enable air bag system referring to Enabling Air Bag System: in Section 8B.

Blower Motor Resistor Inspection

S4RS0A7106006

Measure each terminal-to-terminal resistance. If measured resistance is out of specification, replace blower motor resistor. Blower motor resistor resistance H MH: Approximately 0.6 at 20 25 C (68 77 F) MH ML: Approximately 1.6 at 20 25 C (68 77 F) ML L: Approximately 3.4 at 20 25 C (68 77 F)
MH L

1
I4RS0A710008-

6) Remove foot duct (1) from HVAC unit by removing screw (2).

HI

ML
I4RS0A710011-

1
I4RS0A710009-

7) Remove connector (1) from blower motor resistor (2), and then remove blower motor resistor from HVAC unit by removing screws (3).

1 3

3
I4RS0A710010-

Heater and Ventilation:

7A-7

HVAC Control Unit Components

S4RS0A7106008

1 5

10

8 3 2
I4RS0A710012-

1. Heater control body assembly 2. Airflow selector 3. Blower speed selector

4. Bulb 5. Temperature control cable 6. Airflow control cable

7. Air intake switch 8. Temperature selector 9. A/C switch

10. Rear defogger switch

HVAC Control Unit Removal and Installation

S4RS0A7106010

Removal 1) Disconnect negative () cable at battery. 2) Disable air bag system referring to Disabling Air Bag System: in Section 8B. 3) Remove passenger air bag module from instrument panel referring to Passenger Air Bag (Inflator) Module Removal and Installation: in Section 8B. 4) Remove radio assembly from instrument panel referring to Radio Assembly Removal and Installation: in Section 9C. 5) Remove foot duct (1) from HVAC unit by removing screw (2).
2

I4RS0A710014-

7) Remove two connectors from HVAC control unit. 8) Remove HVAC control unit (1) from instrument panel. NOTE: Be careful not to damage HVAC control unit and instrument panel by using rag.

I4RS0A710013-

6) Disconnect temperature control cable (1) and airflow control cable (2) from HVAC unit.

I4RS0A710015-

7A-8 Heater and Ventilation: Installation Reverse removal procedure noting the following instructions. Connect temperature control cable and airflow control cable of HVAC control unit to links of HVAC unit. a. Set airflow selector (1) to VENT position and temperature selector (2) to MAX COOL position.

3 1

1
I4RS0A710016-

b. Move temperature control lever (1) and airflow control plate (2) fully to the arrow direction.
2 3

I4RS0A710018-

NOTE: After installing control cables, make sure that control lever and plate move smoothly and stop at proper position. Enable air bag system referring to Enabling Air Bag System: in Section 8B. Make sure that airflow outlet changes correctly as airflow selector is changed.
2

Blower Speed Selector Inspection

S4RS0A7106011

Check blower speed selector for each terminal to terminal continuity. If check result does not meet the following conditions, replace HVAC control unit.
I
I4RS0A710017-

MH

c. Fix temperature control inner cable (1) to pin of temperature control lever and air flow control inner cable (2) to pin of airflow control plate, and then fix each outer cable (3) to each cable lock clamp.
Terminal Position

GND

ML

GND

ML

MH

OFF 1 2 3 4
I4RS0A710019-

Heater and Ventilation:

7A-9

Air Intake Switch Inspection

S4RS0A7106018

Check that there is continuity between terminal (1) and terminal (2) when air intake switch is at fresh position. Check that there is no continuity between terminal (1) and terminal (2) and there is continuity between terminal (1) and terminal (3) when air intake switch is at recirculation position. If check result does not meet the above conditions, replace HVAC control unit.
1 2 3

Installation Reverse removal procedure noting the following instruction. Be sure to insert the linkage pin (1) into the groove (2) of air intake control actuator.
1

I4RS0A710022-

Air Intake Control Actuator Inspection

S4RS0A7106019

I4RS0A710020-

Air Intake Control Actuator Removal and Installation

S4RS0A7106020

Check air intake control actuator as follows: 1) Using service wire, connect battery positive terminal to a terminal and battery negative terminal to terminal b. And, check if air intake selector link operates smoothly and it stops at fresh position (1). 2) Using service wire, connect battery positive terminal to a terminal and battery negative terminal to terminal c. And, check if air intake selector link operates smoothly and it stops at recirculation position (2). If malfunction is found, replace air intake control actuator.

Removal 1) Remove instrument panel from vehicle body referring to Instrument Panel Removal and Installation: in Section 9C. 2) Remove screws (1). 3) Remove air intake control actuator (2) from HVAC unit.
1 1

b c

1 2

2
I4RS0A710021I4RS0A710023-

7A-10 Heater and Ventilation:

Center Ventilation Louver Removal and Installation

S4RS0A7106014

Side Ventilation Louver Removal and Installation

S4RS0A7106015

Removal 1) Disconnect negative () cable from battery. 2) Disable air bag system referring to Disabling Air Bag System: in Section 8B. 3) Remove passenger air bag module from instrument panel referring to Passenger Air Bag (Inflator) Module Removal and Installation: in Section 8B. 4) Remove radio assembly from instrument panel referring to Radio Assembly Removal and Installation: in Section 9C. 5) Remove center ventilation louver (1) with garnish (2) from instrument panel, and then disconnect connector from hazard switch. NOTE: Garnish is fitted to instrument panel with six clips. When removing garnish from instrument panel, be careful not to break them. 6) Separate center ventilation louver and garnish.
1

Right side ventilation louver Removal 1) Disconnect negative () cable from battery. 2) Disable air bag system referring to Disabling Air Bag System: in Section 8B. 3) Remove steering column hole cover from instrument panel. 4) Remove combination meter cluster panel from instrument panel, and then disconnect connector from front fog lamp switch of combination meter cluster panel. 5) Separate right side ventilation louver (1) and combination meter cluster (2).

2
I4RS0A710025-

2
I4RS0A710024-

Installation Reverse removal procedure noting the following instruction. Right side ventilation louver is fitted to combination meter cluster panel with four clips (1). When installing right side ventilation louver to combination meter cluster panel, position the smallest clip to the top.

Installation Reverse removal procedure.

I4RS0A710026-

Left side ventilation louver Removal 1) Disconnect negative () cable from battery. 2) Disable air bag system referring to Disabling Air Bag System: in Section 8B. 3) Remove glove box from instrument panel.

Heater and Ventilation: 4) Remove passenger air bag module from instrument panel referring to Passenger Air Bag (Inflator) Module Removal and Installation: in Section 8B. 5) Separate left side ventilation louver (1) and passenger air bag module (2).

7A-11

Installation Reverse removal procedure noting the following instructions. Position air filter by directing its arrow mark to the upward.

1
I4RS0A710030-

2
I4RS0A710027-

Fit air filter cover (1) to HVAC unit so as not to stick air filter (2) by air filter covers claw (3). Otherwise, air filter is deformed and loses its functionality.

Installation Reverse removal procedure noting the following instruction. Left side ventilation louver is fitted to passenger air bag module with four clips (1). When installing left side ventilation louver to passenger air bag module, position the smallest clip to the top.

3 1
I4RS0A710028I4RS0A710031-

Air Filter Cleaning Air Filter Removal and Installation

S4RS0A7106023 S4RS0A7106022

Blow compressed air to the air outlet side of air filter.

Removal 1) Remove glove box from instrument panel. 2) Remove air filter cover (1) from HVAC unit.

I4RS0A710032-

1
I4RS0A710029-

3) Pull out air filter from HVAC unit.

7B-1 Air Conditioning System:

Air Conditioning System

Precautions
A/C System Caution
S4RS0A7200001

CAUTION: The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a). None of refrigerant, compressor oil and component parts is interchangeable between two types of A/ C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12). Be sure to check which refrigerant is used before any service work including inspection and maintenance. For identification between these two types, refer to Refrigerant Type Construction: . When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced. Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.

Precautions on Servicing A/C System

S4RS0A7200004

WARNING: Should refrigerant HFC-134a (R-134a) is exposed to your eye(s), consult a doctor immediately. Do not use your hand to rub affected eye(s). Instead, use fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point. Obtain proper treatment as soon as possible from a doctor or eye specialist. Should liquid refrigerant HFC-134a (R-134a) is exposed to your skin, such affected part should be treated in the same manner as when skin is frostbitten or frozen. Handling Refrigerant HFC-134a (R-134a) Always wear goggles to protect your eyes. Avoid direct contact to liquid refrigerant. Do not heat refrigerant container higher than 40 C (104 F). Do not discharge refrigerant into atmosphere. Do not expose bright metals to liquid refrigerant. Refrigerant combined with moisture is corrosive and tarnishes surfaces of bright metals including chrome. Refrigerant Line : Compressor oil 990009901500A

Air Conditioning System:

7B-2

4 1

5 2

3
I4RS0A720001-

1. Suction hose : Apply compressor oil (refrigerant oil) to O-ring. 2. Discharge hose : Apply compressor oil (refrigerant oil) to O-ring. 3. Liquid pipe : Apply compressor oil (refrigerant oil) to O-ring.

4. Expansion valve : Apply compressor oil (refrigerant oil) to O-ring. 5. A/C refrigerant pressure sensor : Apply compressor oil (refrigerant oil) to O-ring.

Never use heat for bending pipes. When bending a pipe, try to make its bending angle as smooth as possible. Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately. When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to O-ring. When tightening or loosening a fitting, use two wrenches, one for turning and the other for support. Route drain hose so that drained water does not make any contact to vehicle components. If pipes or hoses are replaced, replenish specified amount of compressor oil to compressor suction side referring to Replenishing Compressor Oil in Operation Procedure for Refrigerant Charge: . Refrigerant Recovery When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environments. Refrigerant Charge After performing compressor oil replenishment and evacuation, charge a proper amount of refrigerant to A/C system referring to Charge in Operation Procedure for Refrigerant Charge: .

7B-3 Air Conditioning System:

General Description
Refrigerant Type Construction
S4RS0A7201002

Whether the A/C system in the vehicle uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on label (1) on the compressor. Also, it can be checked by the shape of the service (charge) valve (2).

I4RS0A720002-

[A]: HFC-134a (R-134a) [B]: CFC-12 (R-12)

Sub-Cool A/C System Description

S4RS0A7201004

In the sub-cool A/C system (condenser integrated with receiver / dryer), the inside of the condenser is divided into the condensation part and the sub-cooler part, and the receiver / dryer is located between those. In the receiver / dryer, the refrigerant is separated into the vapor refrigerant and the liquid refrigerant. Only the liquid refrigerant is delivered to the sub-cooler part of the condenser. The refrigerant is supercooled by the sub-cooler part of the condenser.

Air Conditioning System:

7B-4

5 4

: [A] : [B] : [C]

1 3 8 12

10

11

13 9
I4RS0A720051-

[A]: Liquid [B]: Vapor [C]: Superheated vapor 1. Compressor

2. Magnet clutch 3. Condenser 4. Receiver/dryer 5. Refrigerant pressure switch

6. Expansion valve 7. A/C evaporator 8. Condensation part 9. Sub-cooler part

10. Desiccant 11. Filter 12. Vapor refrigerant 13. Liquid refrigerant

7B-5 Air Conditioning System:

Schematic and Routing Diagram

Major Components of A/C System
S4RS0A7202001

Airflow diagram

I4RS0A720003-

Major components of A/C system

8 1 6

5 2

7 3
1. HVAC 2. Compressor 3. Condenser assembly 4. Receiver/dryer 5. Discharge hose 6. Suction hose 7. Liquid pipe 8. Expansion valve

4
I4RS0A720004-

9. Side ventilation air 10. Center ventilation air 11. Foot air 12. Front defroster air

13. Side defroster air 14. Fresh air 15. Recirculation air 16. Evaporator

Air Conditioning System:

7B-6

A/C System Wiring Diagram

S4RS0A7202002

7 10A 10A 10A 4 5 RED/BLK BLK/YEL BLK

2 M BLK/WHT YEL BLU/WHT RED 6 G19-6 G19-7 G19-3 G19-2 G19-5 BRN/WHT G18-6 GRN/WHT RED/BLK M 12 RED GRN BRN BLK/RED RED/YEL BLK G18-13 G18-5 G18-14

G19-1 BLK

G18-9 G18-10 G18-8 G18-7 G18-4 G18-3 BLK/ORN

10 12V 11 BLK/YEL BLK/YEL BLK/YEL BRN/WHT BLK/RED BLK/RED BLU/YEL 14 WHT 13 9 GRY/RED RED ORN 15 80A WHT/BLK ORN 16 LT GRN ORN C37-24 C37-55
I4RS0A720005-

BLU/WHT

E23-19 E23-60

BLK/RED BLK/RED GRY

E23-1 12V E23-16 E23-47 5V

5V C37-14 E23-55 C37-57 5V E23-57 E23-54 5V

5V

1. Ignition switch 2. Blower motor 3. HVAC control unit 4. Lighting switch

5. Blower motor relay 6. Blower motor resistor 7. Junction block assembly 8. BCM

9. A/C refrigerant pressure sensor 10. ECM 11. Main relay 12. Air intake control actuator

13. Compressor relay 14. Compressor 15. Evaporator thermistor (evaporator temperature sensor) 16. ECT sensor

7B-7 Air Conditioning System:

Diagnostic Information and Procedures

A/C System Symptom Diagnosis
S4RS0A7204001

Condition Possible cause No cool air comes out (A/ No refrigerant C system does not operate) Fuse blown A/C switch faulty Blower speed selector faulty

Evaporator thermistor (Evaporator temperature sensor) faulty

A/C refrigerant pressure sensor faulty

Wiring or grounding faulty ECM and/or its circuit faulty Magnet clutch faulty Compressor drive belt loosened or broken Compressor faulty Compressor relay faulty No cool air comes out (radiator cooling fan motor does not operate) Fuse blown Wiring or grounding faulty Radiator cooling fan motor relay faulty

Correction / Reference Item Perform recovery, evacuation and charge referring to Operation Procedure for Refrigerant Charge: . Check related fuses, and then check for short circuit to ground. Check A/C switch referring to A/C Switch Inspection: . Check blower speed selector referring to Blower Speed Selector Inspection: in Section 7A. Check A/C evaporator temperature sensor referring to Evaporator Thermistor (Evaporator Temperature Sensor) Inspection: . Check A/C refrigerant pressure sensor referring to A/C Refrigerant Pressure Sensor Removal and Installation: . Repair as necessary. Check ECM and/or its circuit referring to A/C System Inspection at ECM: . Check magnet clutch referring to Magnet Clutch Inspection: . Adjust or replace drive belt. Check compressor. Check compressor relay referring to Compressor Relay Inspection: . Check related fuses, and then check for short circuit to ground. Repair as necessary. Check radiator cooling fan motor relay referring to Radiator Cooling Fan Relay Inspection: in Section 1F. Check radiator cooling fan motor referring to Radiator Cooling Fan Removal and Installation: in Section 1F. Check ECM and/or its circuit referring to A/C System Inspection at ECM: . Check related fuses, and then check for short circuit to ground. Check blower motor resistor referring to Blower Motor Resistor Inspection: in Section 7A. Check blower speed selector referring to Blower Speed Selector Inspection: in Section 7A. Repair as necessary. Check blower motor referring to Blower Motor Inspection: in Section 7A.

Radiator cooling fan motor faulty

ECM and/or its circuit faulty No cool air comes out (Blower motor does not operate) Fuse blown Blower motor resistor faulty

Blower speed selector faulty

Wiring or grounding faulty Blower motor faulty

Air Conditioning System: Condition Possible cause Insufficient or excessive charge of Cool air does not come out or insufficient cooling refrigerant Condenser clogged (A/C system normal operation) A/C evaporator clogged or frosted

7B-8

A/C evaporator temperature sensor faulty

Expansion valve faulty Desiccant clogged Compressor drive belt loosened or broken Magnet clutch faulty

Correction / Reference Item Check the amount of refrigerant and system for leaks. Check condenser referring to Condenser Assembly On-Vehicle Inspection: . Check A/C evaporator and evaporator thermistor (evaporator temperature sensor) referring to Evaporator Inspection: and Evaporator Thermistor (Evaporator Temperature Sensor) Inspection: . Check A/C evaporator temperature sensor referring to Evaporator Thermistor (Evaporator Temperature Sensor) Inspection: . Check expansion valve referring to Expansion Valve Inspection: . Check desiccant. Adjust or replace drive belt.

Check magnet clutch referring to Magnet Clutch Inspection: . Compressor faulty Check compressor. Air in A/C system Replace desiccant, and then perform evacuation and charge referring to Operation Procedure for Refrigerant Charge: . Air leaking from HVAC unit or air duct Repair as necessary. Heater and ventilation system faulty Check HVAC unit. Blower motor faulty Check blower motor referring to Blower Motor Inspection: in Section 7A. Excessive compressor oil in A/C system Drain excessive compressor oil from A/C system circuit and compressor. Cool air does not come Wiring connection faulty Repair as necessary. out only intermittently Expansion valve faulty Check expansion valve referring to Expansion Valve Inspection: . Excessive moisture in A/C system Replace desiccant, and then perform evacuation and charge referring to Operation Procedure for Refrigerant Charge: . Magnet clutch faulty Check magnet clutch referring to Magnet Clutch Inspection: . Excessive amount of refrigerant Check the amount of refrigerant. Cool air comes out only at Condenser clogged Check condenser referring to Condenser high speed Assembly On-Vehicle Inspection: . Insufficient charge of refrigerant Check the amount of refrigerant and system for leaks. Air in A/C system Replace desiccant, and then perform evacuation and charge referring to Operation Procedure for Refrigerant Charge: . Compressor drive belt loosened or Adjust or replace drive belt. broken Compressor faulty Check compressor. Cool air does not come Excessive amount of refrigerant Check the amount of refrigerant. out only at high speed A/C evaporator frosted Check A/C evaporator and evaporator thermistor (evaporator temperature sensor) referring to Evaporator Inspection: and Evaporator Thermistor (Evaporator Temperature Sensor) Inspection: .

7B-9 Air Conditioning System: Condition Insufficient airflow of cooled air Possible cause A/C evaporator clogged or frosted Correction / Reference Item Check A/C evaporator and evaporator thermistor (evaporator temperature sensor) referring to Evaporator Inspection: and Evaporator Thermistor (Evaporator Temperature Sensor) Inspection: . Repair as necessary. Check blower motor referring to Blower Motor Inspection: in Section 7A. Repair as necessary.

Air leaking from HVAC unit or air duct Blower motor faulty Wiring or grounding faulty

Abnormal Noise Symptom Diagnosis of A/C System

S4RS0A7204002

Abnormal Noise from Compressor Condition During compressor operation, a rumbling noise is heard proportional to engine revolutions A loud noise is heard at a certain rpm, disproportionately to engine revolution A loud rattle is heard at low engine rpm Possible cause Inadequate clearance in scroll area Correction / Reference Item Replace compressor.

Loose or faulty compressor drive belt Loose compressor mounting bolts

Adjust drive belt tension or replace drive belt. Retighten mounting bolts.

Loose compressor clutch plate bolt

Retighten clutch plate bolt. Replace compressor if it was operated in this condition for a long time.

Abnormal Noise from Magnetic Clutch Condition A rumbling noise is heard when compressor is not in operation A chattering noise is heard when compressor is in operation Possible cause Worn or damaged bearings Correction / Reference Item Replace magnet clutch assembly.

Faulty magnet clutch clearance (excessive clearance) Worn magnet clutch friction surface Compressor oil leaked from shaft seal, contaminating the friction surface

Adjust magnet clutch clearance. Replace magnet clutch assembly. Replace compressor body assembly.

Abnormal Noise from Tubing Condition Possible cause A droning noise is heard Faulty tubing clamps from inside of the vehicle, Resonance caused by pulsation from but not particularly variations in refrigerant pressure noticeable in engine compartment Abnormal Noise from Condenser Assembly Condition Possible cause Considerable vibration in Resonance from condenser assembly condenser assembly bracket and body Abnormal Noise from Crankshaft Pulley Condition A large rattling noise is heard at idle or sudden acceleration Possible cause Loosen crankshaft pulley bolt Correction / Reference Item Retighten bolt. Correction / Reference Item Firmly insert a silencer between condenser assembly bracket and body. Correction / Reference Item Reposition clamps or increase the number of clamps. Attach a silencer to tubing, or modify its position and length.

Air Conditioning System: Abnormal Noise from Tension Pulley Condition Clattering noise is heard from pulley Pulley cranks upon contact Possible cause Worn or damaged bearing Cracked or loose bracket Correction / Reference Item Replace tension pulley. Replace or retighten bracket.

7B-10

Abnormal Noise from A/C Evaporator Condition Possible cause Correction / Reference Item At times, slightly decreasing refrigerant volume Whistling sound is heard Depending on the combination of the from A/C evaporator interior / exterior temperatures, engine may stop this noise. Inspect expansion valve and replace if faulty. rpm and refrigerant pressure, the refrigerant flowing out of the expansion valve may, under certain conditions, make a whistling sound Abnormal Noise from Blower Motor Condition Blower motor emits a chirping sound in proportion to its speed of rotation Fluttering noise or large droning noise is heard from blower motor Possible cause Worn or damaged motor brushes or commutator Correction / Reference Item Replace blower motor.

Leaves or other debris introduced from Remove debris and make sure that the screen fresh air inlet to blower motor at fresh air inlet is intact.

A/C System Performance Inspection

S4RS0A7204003

CAUTION: Do not connect high and low pressure charging hoses in reverse.

1) Confirm that vehicle and environmental conditions are as follows. Vehicle is put indoors. Ambient temperature is within 25 35 C (77 95 F). Relative humidity is within 30 70%. There is no wind indoors. HVAC unit is normal. Blower motor is normal. There is no air leakage from air ducts. Condenser fins are clean. Are filter is not clogged with dirt and dust. Battery voltage is about 12 V. Radiator cooling fan operates normally. 2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly closed. 3) Connect high pressure charging hose (3) to high pressure service valve (5) on vehicle and low pressure charging hose (4) to low pressure service valve (6). 4) Bleed the air in charging hoses (3) and (4) by loosening their nuts respectively utilizing the refrigerant pressure. When a hissing sound is heard, immediately tighten nut.

1 2 4 6 3

I4RS0A720006-

5) Warm up engine to the normal operating temperature and keep it at the specified idle speed. 6) Turn A/C switch ON, set blower speed selector at maximum speed position, temperature selector at maximum cold position, airflow selector at face position, and air intake switch at recirculation position. (Confirm that A/C compressor and condenser fans are working.) 7) Wait for ten minutes to stabilize the A/C operation.

7B-11 Air Conditioning System: 8) Open front windows, front doors and engine food. 9) With about 20 mm (0.8 in.) of dry bulb thermometer (1) put right in front of center ventilation louver and a wet and dry bulb thermometer (2) near air inlet of HVAC unit.

I4RS0A720007-

10) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out of specified pressure, correct defective part referring to the following table. NOTE: Pressure registered on gauge varies with ambient temperature. Therefore, use the graphs when determining if pressures are normal or not. Low side and high side pressure example, Gauges should read as follows when ambient temperature is 30 C (86 F) Pressure on high pressure gauge (HI): 1240 1520 kPa (12.4 15.2 kg/cm2) Pressure on low pressure gauge (LO): 250 360 kPa (2.5 3.6 kg/cm2)
psi kPa kg/cm 284.4 2000 20 270.2 256.0 241.7 227.5 Pressure of High Pressure Gauge 213.3 199.1 184.9 170.6 151.4 142.2 128.0 113.8 99.5 85.3 Pressure of Low Pressure Gauge 71.1 56.9 42.7 28.4 14.2 1900 19 1800 18 1700 17 1600 16 1500 15 1400 14 1300 13 1200 12 1000 10 900 800 700 600 500 400 300 200 100 9 8 7 6 5 4 3 2 1 0 25 77 D 30 86 Ambient Temperature 35 C 95 F
I4RS0A7200082

70 A

Acceptable range

30

C
Acceptable range

70 30

Humidity

1100 11

Air Conditioning System: High pressure gauge Condition Pressure is higher than acceptable range (A area)

7B-12

Possible cause Refrigerant overcharged Expansion valve frozen or clogged Clogged refrigerant passage of high pressure side Radiator cooling fan malfunction (Insufficient cooling of condenser) Dirty or bent condenser fins (Insufficient cooling of condenser) Compressor malfunction (Insufficient oil etc.) Engine overheat

Correction Recharge. Check expansion valve. Clean or replace. Check radiator cooling fan. Clean or repair. Check compressor. Check engine cooling system referring to Engine Cooling Symptom Diagnosis: in Section 1F. Check for leakage, repair if necessary and recharge. Check expansion valve. Check compressor.

Pressure is lower than acceptable range (B area)

Insufficient refrigerant (Insufficient charge or leakage) Expansion valve malfunction (valve opens too wide) Compressor malfunction (Insufficient compression)

Low pressure gauge Condition Pressure is higher than acceptable range (C area) Pressure is lower than acceptable range (D area)

Possible cause Expansion valve malfunction (valve opens too wide) Compressor malfunction (Insufficient compression) Insufficient refrigerant (Insufficient charge or leakage) Expansion valve malfunction (valve opens too narrow) Clogged refrigerant passage (crashed pipe)

Correction Check expansion valve. Check compressor. Check for leakage, repair if necessary and recharge. Check expansion valve. Repair or replace.

11) Check inlet port temperature-to-outlet port temperature relationship using the graph. For example, if temperature near air inlet of HVAC unit is 30 C (86 F) and the one at air outlet of center ventilation louver is 17 C (62.6 F), their crossing point is within acceptable range as shown in the graph. In this case, cooling performance is satisfactory and proper. 12) If crossing point is out of acceptable range, diagnose trouble referring to the following table.

7B-13 Air Conditioning System:

F C 82.4 28 80.6 27 78.8 26 Temp. at Air Outlet of Center Ventilation Louver 77.0 25 75.2 24 73.4 23 71.6 22 69.8 21 68.0 20 66.2 19 64.4 18 62.6 17 60.8 16 59.0 15 57.2 14 55.4 13 53.6 12 51.8 11 50.0 10 48.2 46.4 9 8 F
Acceptable range

% 70

E Humidity 30 25 30 35 C 77 86 95 F Temp. near Air Inlet of HVAC unit

I4RS0A720009-

Thermometer at center duct Condition Possible cause Crossing point is higher Insufficient or excessive charge of refrigerant than acceptable range Dirty or bent A/C evaporator fins (E area) Air leakage from cooling (heater) unit or air duct Malfunctioning, switch over function of door in cooling (heater) unit Compressor malfunction Crossing point is lower Insufficient air volume from center duct (Heater than acceptable range blower malfunction) (F area) Compressor malfunction NOTE:

Correction Check refrigerant pressure. Clean or repair. Repair or replace. Repair or replace. Check compressor. Check blower motor and fan. Check compressor.

If ambient temperature is approximately 30 C (86 F), it is possible to diagnose A/C system in detail referring to the following table. Condition MPa (kg/cm2) (psi) Hi 1.24 1.52 (12.4 15.2) (176 216) 0.5 0.6 (5 6) (71.2 85.3)

Manifold gauge Lo 0.23 0.36 (2.3 3.6) (33 51) Negative pressure

Detail Normal condition

Possible cause

Correction

The low pressure side reads a negative pressure, and the high pressure side reads an extremely low pressure. Presence of frost around tubing to and from receiver/dryer and expansion valve. Dust particles or water droplets are either stuck or frozen inside expansion valve, preventing the refrigerant from flowing.

Clean expansion valve. Replace it if it cannot be cleaned. Replace receiver/dryer. Evacuate the A/C system and recharge with fresh refrigerant.

Air Conditioning System: Condition MPa (kg/cm2) (psi) Hi Normal: 1.24 1.52 (12.4 15.2) (176 216) Abnormal: 0.7 1.0 (7 10) (100 142) 0.7 1.0 (7 10) (100 142)

7B-14

Manifold gauge Lo Normal: 0.23 0.36 (2.3 3.6) (33 51) Abnormal: Negative pressure

Detail During A/C operation, the low pressure side sometimes indicates negative pressure, and sometimes normal pressure. Also high pressure side reading fluctuates between the abnormal and normal pressure. Both low and high pressure sides indicate low readings. Output air is slightly cold.

Possible cause Expansion valve is frozen due to moisture in the system, and temporarily shuts off the refrigeration cycle.

Correction Replace expansion valve. Replace desiccant. Evacuate A/C system and recharge with fresh refrigerant.

0.05 0.15 (0.5 1.5) (4.2 21.3)

0.4 0.6 (4 6) (56.9 85.3)

0.35 0.45 (3.5 4.5) (50 64)

2.0 2.5 (20 25) (285 355)

0.45 0.55 (4.5 5.5) (64 78)

Insufficient refrigerant Using leak detector, in system check for leaks and (Refrigerant leaking). repair as necessary. Recharge refrigerant to a specified amount. If the pressure reading is almost 0 when the manifold gauges are attached, check for any leaks, repair them, and evacuate the system. Inspect compressor Pressure on low pressure Internal leak in compressor. and repair or replace side is high. as necessary. Pressure on high pressure side is low. Both pressure becoming equal right after A/C is turned OFF. High pressure reading on Overcharged A/C Adjust refrigerant to both low and high pressure system. specified amount. sides. Faulty condenser Clean condenser. cooling operation. Faulty radiator cooling Inspect and repair fan operation. radiator cooling fan. High pressure reading on Presence of air in A/C Replace desiccant. Inspect quantity of both low and high pressure system compressor oil and (Improperly sides. presence of Low pressure side tubing evacuated). contaminants in oil. is not cold when touched. Evacuate system and recharge with fresh refrigerant. Replace expansion High pressure reading on Faulty expansion valve. both low and high pressure valve. Refrigerant flow is not sides. regulated properly. Large amount of frost or dew on the low pressure side tubing.

7B-15 Air Conditioning System:

A/C System Inspection at ECM

S4RS0A7204004

Voltage Check ECM and its circuits can be checked at ECM wiring couplers by measuring voltage. CAUTION: ECM connectors are waterproofed. Each terminal of the ECM connectors is sealed up with the grommet. Therefore, do not measure circuit voltage and resistance by inserting the testers probe into the sealed terminal at the harness side. Or, ECM and its circuits may be damaged by water. ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from ECM. 1) Remove ECM from its bracket referring to Engine Control Module (ECM) Removal and Installation: in Section 1C. 2) Connect ECM couplers to ECM. 3) Check voltage at each terminal. NOTE: As each terminal voltage is affected by the battery voltage, confirm that the battery voltage is 11 V or more when ignition switch is ON position.

I4RS0A720050-

Terminal arrangement of ECM coupler (Viewed from harness side)

E23 15 14 30 29 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 30 29 C37 13 12 11 10 9 8 7 6 5 4 3 2 1 28 27 26 25 24 23 22 21 20 19 18 17 16

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46

45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46
I4RS0A720010-

Air Conditioning System: ECM Voltage Values Table for Relation of A/C Control Terminal Wire Color Circuit Normal Value Output of 5 V C37-14 GRY/RED 4.5 5.5 V power source Engine coolant 3.3 3.6 V C37-24 LT GRN temp. (ECT) 1.1 1.5 V sensor signal C37-55 ORN Ground for sensors Below 0.3 V C37-57 ORN Ground for sensors Below 0.3 V C37-58 BLK/ORN Ground for ECM Below 0.3 V E23-1 BLK/RED Main power supply 10 14 V E23-16 BLK/RED Main power supply 10 14 V E23-19 BLU/WHT Electric load signal for blower motor A/C compressor relay output Ground for sensors A/C refrigerant pressure sensor signal 10 14 V 01V 10 14 V 01V Below 0.3 V 1.46 1.71 V

7B-16

Condition Ignition switch turned ON Ignition switch turned ON, ECT at 0 C (32 F) Ignition switch turned ON, ECT at 50 C (122 F) Ignition switch turned ON Ignition switch turned ON Ignition switch turned ON Ignition switch turned ON Ignition switch turned ON Ignition switch turned ON, blower fan selector at OFF position Ignition switch turned ON, blower fan selector at 2nd speed position or more Engine running, A/C request signal high input Engine running, A/C request signal low input Ignition switch turned ON Engine running, A/C refrigerant pressure at 0.8 MPa (8.0 kg/cm2)(A/C refrigerant pressure measured by manifold gauge) Engine running, A/C refrigerant pressure at 1.6 MPa (16.0 kg/cm2)(A/C refrigerant pressure measured by manifold gauge) Ignition switch turned ON, evaporator thermistor (evaporator temperature sensor) at 0 C (32 F) Ignition switch turned ON, evaporator thermistor (evaporator temperature sensor) at 15 C (59 F) Ignition switch turned ON, evaporator thermistor (evaporator temperature sensor) at 30 C (86 F) Ignition switch turned OFF Ignition switch turned ON

E23-47 E23-54

GRY ORN

E23-55

RED

2.55 2.80 V 3.45 3.65 V 2.55 2.85 V 1.7 2.1 V 10 14 V 02V

E23-57

WHT/BLK

Evaporator thermistor (evaporator temperature sensor) signal Main power supply relay output

E23-60

BRN/WHT

7B-17 Air Conditioning System:

Repair Instructions
Operation Procedure for Refrigerant Charge
S4RS0A7206002

WARNING: Your eyes should not be exposed to refrigerant (liquid). Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately 6 C (21.2 F) below freezing point. Should liquid HFC-134a (R-134a) is exposed to your eyes, it may cause a serious injury. To protect your eyes from such accident, it is necessary to always wear goggles. Should it occur that HFC-134a (R-134a) is exposed to your eyes, consult a doctor immediately. Do not use your hand to rub the affected eye(s). Instead, use fresh cold water to splash it over the affected area to gradually raise temperature of such area above freezing point. Obtain proper treatment as soon as possible from a doctor or eye specialist. Should the liquid refrigerant HFC-134a (R-134a) is exposed to your skin, the affected area should be treated in the same manner as when skin is frostbitten or frozen. Do not handle refrigerant near any place where welding or steam cleaning is performed. Refrigerant should be kept in a cold and dark place. It should never be stored in any place where temperature is high, e.g. where exposed to direct sun light, close to fire or inside vehicle (including trunk room). Avoid breathing fume produced when HFC-134a (R-134a) is burned. Such fume may be hazardous to your health.

Start evacuation. 10 minutes (above 760 mmHg) Stop evacuation. Wait 10 minutes Check A/C system for pressure tighteness. Inspect and repair connections. If gauge shows abnormal conditions

Recharge A/C system with refrigerant.

Recharge 370 refrigerant.

20 g of

Check A/C system for refrigerant leaks and amount of refrigerant charged.

Performance test
I4RS0A720011-

Air Conditioning System: Recovery When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling equipment because discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environments. NOTE: After recovering refrigerant from system, the amount of removed compressor oil must be measured for replenishing compressor oil. When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.

7B-18

When charging refrigerant only When charging refrigerant without replacing any component , replenish the same amount of measured oil when recovering refrigerant (if not measure, replenish 30 cm3 (30 cc) oil). When replacing compressor CAUTION: Be sure to use P/N: 99000-99015-00A compressor oil or an equivalent compressor oil. Compressor oil is sealed in each new compressor by the amount required for A/C system. Therefore, when using a new compressor, drain the calculated amount of oil from it. C = A B C: Amount of oil to be drained A: Amount of oil in a new compressor B: Amount of oil in removed compressor Oil amount in compressor 90 5 cm3 (80 5 cc, 4.88 0.31 in3)

I4RS0A720012-

Replenishing Compressor Oil It is necessary to replenish specified amount of compressor oil to compressor from compressor suction side hole (1) before evacuating and charging refrigerant.

I2RH01720015-

1. New compressor 2. Removed compressor

When replacing other parts Replenish the following amount of oil to compressor. Amount of compressor oil to be replenished Evaporator: 25 cm3 (25 cc, 1.53 in3) Condenser: 15 cm3 (15 cc, 0.92 in3) Dryer: 20 cm3 (20 cc, 1.22 in3) Hoses: 10 cm3 (10 cc, 0.61 in3) each Pipes: 10 cm3 (10 cc, 0.61 in3) each
1
I4RS0A720013-

7B-19 Air Conditioning System: Evacuation

3

CAUTION: Do not evacuate before recovering refrigerant in A/C system. NOTE: Once air conditioning system circuit is opened (exposed) to atmospheric air, system must be evacuated by using a vacuum pump. The A/C system should be attached with a manifold gauge set, and should be evacuated for approximately 15 minutes. 1) Connect high charging hose (1) and low charging hose (2) of manifold gauge set (3) respectively as follows: High charging hose High pressure charging valve (4) on condenser outlet pipe Low charging hose Low pressure charging valve (5) on suction pipe 2) Attach center charging hose (6) of manifold gauge set to vacuum pump (7). 3) Operate vacuum pump, and then open discharge side valve (Hi) (8) of manifold gauge set. If there is no blockage in the system, there will be an indication on high pressure gauge (9). In this case, open the other side valve (Lo) (10) of the set and repair the system. 4) Approximately 10 minutes later, low pressure gauge (11) should show a vacuum lower than 100 kPa ( 1.0 kg/cm2, 760 mmHg, 14.7 psi) providing no leakage exists. NOTE: If the system does not show a vacuum below 100 kPa (1.0 kg/cm2, 760 mmHg, 14.7 psi), close both valves, stop vacuum pump and watch movement of low pressure gauge. Increase in the gauge reading suggests existence of leakage. In this case, repair the system before continuing its evacuation. If the gauge shows a stable reading (suggesting no leakage), continue evacuation. 5) Evacuation should be carried out for a total of at least 15 minutes. 6) Continue evacuation until low pressure gauge indicates a vacuum less than 100 kPa (1.0 kg/cm2, 760 mmHg, 14.7 psi), and then close both valves. 7) Stop vacuum pump. Disconnect center charging hose from pump inlet. Now, the system is ready for charging refrigerant.

11

10 6 2 1

7 5

I4RS0A720014-

Checking A/C System for Pressure Leaks After completing the evacuation, close manifold gauge high pressure valve and low pressure valve and wait 10 minutes. Verify that low pressure gauge reading has not changed. CAUTION: If the gauge reading moves closer to 0, there is a leak somewhere. Inspect the tubing connections and make necessary corrections. And then, evacuate system once again and make sure that there are no leaks.

Air Conditioning System: Charge CAUTION: Because the sight glass is not used for this A/C system, do not perform an additional charge to the A/C system. To charge the proper amount of refrigerant, recover and evacuate the A/C system first. And then, charge the proper amount of refrigerant into the A/C system. Always charge refrigerant through low pressure side of A/C system after the initial charge is performed from the high pressure side with the engine stopped. Never charge refrigerant through high pressure side of A/C system with engine running. Do not charge refrigerant while compressor is hot. When installing tap valve to refrigerant container to make a hole there through, carefully follow directions given by manufacturer. A pressure gauge should always be used before and during refrigerant charge. The refrigerant container should be emptied of refrigerant when discarding it. The refrigerant container should not be heated up to 40 C (104 F) or over. Refrigerant container should not be reversed in direction during refrigerant charge. Reversing in direction causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid refrigerant and the like. NOTE: The air conditioning system contains HFC134a (R-134a). Described here is a method to charge the air conditioning system with refrigerant from the refrigerant service container. When charging refrigerant recovered by using the refrigerant and recycling equipment (when recycling refrigerant), follow the procedure described in the equipment manufacturers instruction manual.

7B-20

The initial charge of the A/C system is performed through the high pressure side with the engine stopped. And next, this method must be followed by charging from the low pressure side with the engine running. 1) Check if hoses are routed properly after evacuating the system. 2) Connect low charging hose (1) and high charging hose (2) of the manifold gauge set (3) in position. Then, open refrigerant container valve (4) to purge the charging line. 3) Open the high pressure side valve (5) and charge refrigerant to system. 4) After a while, open the low pressure side valve (6) and close the high pressure side valve. WARNING: Make sure that high pressure side valve is closed securely. 5) Start engine and keep engine speed at 1500 r/min, and then operate A/C system. 6) Charge A/C system with refrigerant in vapor state. At this time, refrigerant container should be held upright.
3 5 6 1 2 4

I4RS0A720015-

7) When refrigerant container (1) is emptied, use the following procedure to replace it with a new refrigerant container. a) Close low pressure valve.

7B-21 Air Conditioning System: b) Replace empty container with a refrigerant container which has been charged with refrigerant. When using refrigerant container tap valve (2), use the following procedure for replacement. i) Retract needle (3) and remove refrigerant container tap valve by loosening its plate nut (4). ii) Install the refrigerant container tap valve to a new refrigerant container. 8) After the system has been charged with specified amount (370 20 g) of refrigerant or when low pressure gauge (1) and high pressure gauge (2) have indicated the following specified value, close low pressure side valve (3) on manifold gauge set (4). Low side and high side pressure example Gauges should read as follows when ambient temperature is 30 C (86 F). Pressure 1240 1520 kPa on high pressure gauge 12.4 15.2 kg/cm2 176 216 psi Pressure 250 360 kPa on low pressure gauge 2.5 3.5 kg/cm2 35.6 51 psi

4 2 1 3
I2RH01720018-

c) Purge any air existing in center charging hose. When using refrigerant container tap valve, use the following procedure to purge air. i) Once fully tighten refrigerant container tap valve (1), and then loosen (open) plate nut (2) slightly. ii) Open low pressure side valve (3) of manifold gauge set (4) a little. iii) As soon as refrigerant comes out with a hiss through a clearance between refrigerant container and tap valve, tighten plate nut as well as low pressure side valve. iv) Turn handle of tap valve clockwise so that its needle is screwed into the new container to make a hole for refrigerant flow.

I4RS0A720016-

Removal of Manifold Gauge Set WARNING: High pressure side is under high pressure. Therefore, be careful not to get injured especially on your eyes and skin. For the A/C system charged with the specified amount of refrigerant, remove manifold gauge set as follows: 1) Close low pressure side valve of manifold gauge set. (The high pressure side valve is closed continuously during the process of charging.) 2) Close refrigerant container valve. 3) Stop engine. 4) Using shop rag, remove charging hoses from service valves. This operation must be performed guickly. 5) Put caps on service valves.

I2RH01720019-

Air Conditioning System: Check A/C System for Refrigerant Leaks Whenever a refrigerant leak is suspected in the system or any service operation has been performed which may result in malfunction of lines and connections, it is advisable to check for leaks. Common sense should be used during refrigerant leak test, since the need and extent of any such test will, in general, depend upon the nature of a complaint and the type of a service performed on the system. Liquid leak detector WARNING: To prevent explosions and fires, make sure that there are no flammables in the vicinity. When the refrigerant exposed to fire, it turns into a poisonous gas (phosgene). Do not inhale this gas. There is a number of fittings and places throughout the A/C system where a liquid leak detector solution may be used to pinpoint refrigerant leaks. By merely applying the solution to the area in question with a swab, such as attached to the cap of a vial, bubbles will form within seconds if there is a leak. For confined areas, such as sections of the evaporator and condenser, an electronic (refrigerant) leak detector is more practical for determining leaks. Special tool (A): 09990-86011
2

7B-22

Condenser Assembly Removal and Installation

S4RS0A7206007

CAUTION: Do not damage condenser fins. If condenser fin is bent, straighten it by using flat head screwdriver or pair of pliers. Removal 1) Recover refrigerant from A/C system referring to Operation Procedure for Refrigerant Charge: . NOTE: The amount of removed compressor oil must be measured for replenishing compressor oil. 2) Remove front bumper referring to Front Bumper and Rear Bumper Components: in Section 9K. 3) Disconnect discharge hose (1) and liquid pipe (2) from condenser assembly (3). 4) Remove condenser assembly mounting bolts (4).
4 1

I4RS0A720017-

5) Remove condenser assembly (1) as shown.

I2RH01720020-

Condenser Assembly On-Vehicle Inspection

S4RS0A7206008

Check the followings. Clog of condenser fins If any clog is found, condenser fins should be washed with water and should be dried with compressed air. Condenser fins for leakage and breakage If any defects are found, repair or replace condenser. Condenser fittings for leakage. If any defects are found, repair or replace condenser.

I4RS0A720018-

7B-23 Air Conditioning System: Installation Reverse the removal procedure to install condenser noting the following instructions. Replenish specified amount of compressor oil to compressor suction side referring to Replenishing Compressor Oil in Operation Procedure for Refrigerant Charge: . Evacuate and charge the A/C system referring to Evacuation and Charge in Operation Procedure for Refrigerant Charge: .

Desiccant Removal and Installation

S4RS0A7206009

Removal 1) Remove condenser assembly referring to Condenser Assembly Removal and Installation: . 2) Remove cap (1) from receiver/dryer tank. 3) Remove desiccant (2) from receiver/dryer tank.
2

I4RS0A720019-

Installation Reverse the removal procedure noting the following instructions. Replenish specified amount of compressor oil to compressor suction side referring to in Operation Procedure for Refrigerant Charge: . Do not remove desiccant from the plastic bag until just before inserting it into the receiver. Install the desiccant with its welded part downward. Apply compressor oil to caps O-ring. Tighten cap to the specified torque Tightening torque Cap (a): 3.0 Nm (0.3 kg-m, 2.5 lb-ft) Evacuate and charge the A/C system referring to Evacuation and Charge in Operation Procedure for Refrigerant Charge: .

(a)

I4RS0A720020-

Air Conditioning System:

7B-24

HVAC Unit Components

S4RS0A7206003

2 20 5 21 7 18

6 15 2 7 8 15 15

9 8 10 13 17 23 14

14

11 20 16 6

19

22

12

I4RS0A720021-

1. Fresh air inlet duct 2. Blower upper case 3. Air intake control actuator 4. Air filter 5. Heater unit upper case

7. Airflow control door assembly 8. Temperature control door assembly 9. Blower motor resistor 10. Blower lower case 11. Blower motor

13. Heater core 14. Temperature control lever 15. Airflow control lever 16. Evaporator 17. O-ring

19. Evaporator thermistor (evaporator temperature sensor) 20. Packing 21. Filter cover 22. Drain hose 23. Cable lock clamp

7B-25 Air Conditioning System:

6. Foot duct 12. Heater unit lower case 18. Expansion valve : Do not reuse.

HVAC Unit Removal and Installation

S4RS0A7206012

Removal 1) Disconnect negative () cable from battery. 2) Disable air bag system referring to Disabling Air Bag System: in Section 8B. 3) Recover refrigerant from A/C system with recovery and recycling equipment referring to Recovery in Operation Procedure for Refrigerant Charge: . 4) Remove cowl top panel referring to Cowl Top Components: in Section 9K. 5) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2). 6) Remove instrument panel from vehicle body referring to Instrument Panel Removal and Installation: in Section 9C. 7) Loosen suction hose and liquid pipe bolt (4). 8) Remove nuts (3). 9) Remove HVAC unit from vehicle body.
3 2 3

1
I4RS0A720023-

Evacuate and charge the A/C system referring to Evacuation and Charge in Operation Procedure for Refrigerant Charge: . Adjust control cables referring to HVAC Control Unit Removal and Installation: in Section 7A. Enable air bag system referring to Enabling Air Bag System: in Section 8B.

Evaporator Inspection
S4RS0A7206013

3 1

Check the followings. Clog of A/C evaporator fins. If any clogs are found, A/C evaporator fins should be washed with water, and then should be dried with compressed air. A/C evaporator fins for leakage and breakage. If any defects are found, repair or replace A/C evaporator. A/C evaporator fittings for leakage. If any defects are found, repair or replace A/C evaporator.

4
I4RS0A720022-

Evaporator Thermistor (Evaporator Temperature Sensor) Removal and Installation

S4RS0A7206033

Installation Reverse removal procedure noting the following instructions. Replenish specified amount of compressor oil to compressor suction side referring to Replenishing Compressor Oil in Operation Procedure for Refrigerant Charge: . Install the padding (1) to the installation hole uniformly.

Removal 1) Disconnect negative () cable from battery. 2) Remove HVAC unit from vehicle body referring to HVAC Unit Removal and Installation: . 3) Remove evaporator thermistor (evaporator temperature sensor) (1) from evaporator by disassembling HVAC unit.

Air Conditioning System:

7B-26

1
I4RS0A720052-

Installation Reverse the removal procedure noting the following instruction. Install evaporator thermistor (evaporator temperature sensor) (1) onto evaporator (2) as shown.

4 5
I4RS0A720027-

[A]: Resistance (k) [B]: Temperature

Expansion Valve Removal and Installation

S4RS0A7206015

1
I4RS0A720053-

3. 50 5 mm (2 0.2 in.) 4. Sensor part fixed to 10th fin from the bottom 5. Holding part fixed to 8th fin from the bottom

Evaporator Thermistor (Evaporator Temperature Sensor) Inspection

S4RS0A7206014

Removal 1) Recover refrigerant from the A/C system with recovery and recycling equipment referring to Recovery in Operation Procedure for Refrigerant Charge: . 2) Loosen a bolt (1) and remove pipes from expansion valve (2). 3) Loosen bolts (3) and remove expansion valve.

Check resistance between terminals of evaporator thermistor (1). If check results are as not specified, replace evaporator thermistor. Evaporator themistor resistance 0 C (32 F): 6.6 6.9 k 25 C (77 F): 1.9 2.3 k
2

1 3

2
I4RS0A720028-

7B-27 Air Conditioning System: Installation Reverse removal procedure noting the following instructions. Apply compressor oil to O-ring of expansion valve and pipes. Evacuate and charge the A/C system referring to Evacuation and Charge in Operation Procedure for Refrigerant Charge: .

Expansion Valve Inspection

S4RS0A7206016

1
I4RS0A720029-

Refer to A/C System Performance Inspection:

A/C Refrigerant Pressure Sensor and Its Circuit Inspection

S4RS0A7206034

1) Disconnect A/C refrigerant pressure sensor connector. 2) Turn ignition switch to ON position. 3) Check if voltage between RED wire terminal and ORN wire terminal of A/C refrigerant pressure sensor connector is 4.75 V to 5.25 V. If not, check A/C refrigerant pressure sensor circuit. 4) Connect A/C refrigerant pressure sensor connector with ignition switch turned OFF. 5) Connect manifold gauge set to the charging valves. 6) Check A/C refrigerant pressure sensor voltage of ECM connector referring to A/C System Inspection at ECM: . If voltage is not as specified below, replace A/C refrigerant pressure sensor. A/C refrigerant pressure sensor voltage specifications (A/C refrigerant pressure measured by manifold gauge) 0.8 MPa (8.0 kg/cm2, 116 psi): 1.46 1.71 V 1.4 MPa (14 kg/cm2, 203 psi): 2.28 2.53 V 1.6 MPa (16 kg/cm2, 232 psi): 2.55 2.80 V 1.8 MPa (18 kg/cm2, 261 psi): 2.82 3.03 V

Installation. Reverse removal procedure noting the following instructions. Apply compressor oil to O-ring of A/C refringerant pressure sensor. Tighten A/C refrigerant pressure sensor to specified torque. Tightening torque A/C refrigerant pressure sensor (a): 11 Nm (1.1 kg-m, 8.0 lb-ft)

(a)
I4RS0A720031-

Evacuate and charge system referring to Evacuation and Charge in Operation Procedure for Refrigerant Charge: .

A/C Switch Inspection

S4RS0A7206035

A/C Refrigerant Pressure Sensor Removal and Installation

S4RS0A7206018

Removal 1) Recover refrigerant from the A/C system with the recovery and recycling equipment referring to Recovery in Operation Procedure for Refrigerant Charge: . 2) Disconnect negative () cable from battery. 3) Disconnect A/C refrigerant pressure sensor connector. 4) Remove A/C refrigerant pressure sensor (1) from liquid pipe (2).

Check that there is continuity between terminal (1) and terminal (2) when A/C switch is at ON position. Check that there is no continuity between terminal (1) and terminal (2) when A/C switch is at OFF position. If check result does not meet the above conditions, replace HVAC control unit.

Air Conditioning System:

7B-28

Compressor Drive Belt Inspection and Adjustment

S4RS0A7206021

Inspection Check compressor drive belt (1) for wear, crack, deformation and cleanliness. If any defect is found, replace the belt with new one referring to Compressor Drive Belt Removal and Installation: . Check compressor drive belt tension by measuring how much it deflects when pushed intermediate point between tension pulley (2) and crankshaft pulley (3) with about 100 N (10 kg) force after rotating crankshaft pulley 360. If belt tension is out of specification, adjust belt tension referring to Adjustment. Compressor drive belt tension a: 7 8mm (0.28 0.31 in.)
I4RS0A720030-

Compressor Relay Inspection

S4RS0A7206019

New compressor drive belt tension a: 6 7mm (0.24 0.28 in.) Adjustment 1) Loosen tension pulley nut (4). 2) Adjust belt tension by tighten or loosen tension pulley adjusting bolt (5). 3) Tighten tension pulley nut. 4) Rotate the crankshaft pulley 360, and then recheck belt tension.

1) Disconnect negative () cable from battery. 2) Remove compressor relay (1) from main fuse box. 3) Check that there is no continuity between terminal c and d. If there is continuity, replace relay. 4) Connect battery positive (+) terminal to terminal b of relay and battery negative () terminal to terminal a of relay, and then check continuity between terminal c and d. If there is no continuity, replace relay.

"a"

"c"

"b"

"d"
6. Magnet clutch pulley

I4RS0A720033-

I4RS0A720032-

7B-29 Air Conditioning System:

Compressor Drive Belt Removal and Installation

S4RS0A7206036

NOTE: Cap open fittings immediately to keep moisture out of the system.

Removal 1) Loosen tension pulley nut (1). 2) Loosen belt tension by loosening tension pulley adjusting bolt (2). 3) Remove compressor drive belt (3).

1 2

4
I4RS0A720035-

9) Remove compressor mounting bolts (1), and then remove compressor (2) from its bracket.
1

I4RS0A720034-

Installation Reverse removal procedure noting the following instruction. Adjust belt tension referring to Compressor Drive Belt Inspection and Adjustment: .

1
I4RS0A720036-

Compressor Assembly Removal and Installation

S4RS0A7206037

Removal 1) Run engine at idle speed with A/C ON for 10 minutes. 2) Stop the engine. 3) Disconnect negative (-) cable from battery. 4) Recover refrigerant from the A/C system with recovery and recycling equipment referring to Recovery in Operation Procedure for Refrigerant Charge: . 5) Remove compressor drive belt referring to Compressor Drive Belt Removal and Installation: . 6) Remove right side engine under cover. 7) Disconnect magnet clutch lead wire coupler (1). 8) Disconnect discharge hose (2) and suction hose (3) from compressor (4).

Installation Reverse removal procedure noting the following instructions. If compressor is replaced, pour new compressor oil referring to Replenishing Compressor Oil in Operation Procedure for Refrigerant Charge: . Evacuate and charge system referring to Evacuation and Charge in Operation Procedure for Refrigerant Charge: . Adjust drive belt tension referring to Compressor Drive Belt Inspection and Adjustment: .

Air Conditioning System:

7B-30

Compressor Assembly Components

S4RS0A7206024

(b)

4 1 (a) 5
I4RS0A720037-

4 7

1. Armature plate bolt 2. Compressor 3. Relief valve

4. Circlip 5. Shim 6. Magnet clutch coil and thermal switch

7. Magnet clutch pulley 8. Armature plate 9. O-ring

: Do not reuse. : 15 Nm (1.5 kg-m, 11.0 lb-ft) : 8 Nm (0.8 kg-m, 6.0 lb-ft)

Magnet Clutch Inspection

S4RS0A7206023

Magnet Clutch Removal and Installation

S4RS0A7206025

Check armature plate and magnet clutch pulley for wear and oil soak respectively. Check magnet clutch pulley bearing for noise, wear and grease leakage. Measure magnet clutch coil for resistance at 20 C (68 F). If the measured resistance does out of specification, replace magnet clutch assembly. Magnet clutch coil resistance Standard: 3.5 4.0

Removal 1) Remove compressor from vehicle referring to Compressor Assembly Removal and Installation: . 2) Fix armature plate (1) with special tool and remove armature plate bolt (2). Special tool (A): 0999106310 3) Remove armature plate (1).

2 1 (A)

I4RS0A720038-

I4RS0A720039-

7B-31 Air Conditioning System: 4) Remove shims from shaft. 5) Remove circlip (1) using special tool. Special tool (B): 0990006107
(B)

Installation 1) Install magnet clutch coil (2) fitting protrusion (4) of magnet clutch coil onto hole (5) of compressor (3). 2) Install new circlip (1) directing chamfer side (6) downward. Special tool (B): 09900-06107
(B)

1 6 2
I4RS0A720040-

6) Remove magnet clutch pulley (2). NOTE: If it is difficult to remove magnet clutch pulley by hand, use puller (1). Do not damage magnet clutch pulley when using puller.
3 5

I4RS0A720043-

3) Apply silicon to contact face of thermal switch. 4) Install magnet clutch lead wire clamp. 5) Install magnet clutch pulley (1). 6) Install new circlip (2) directing chamfer side (3) upward. Special tool (B): 0990006107

1 2

(B)

3
I4RS0A720041-

7) Remove magnet clutch lead wire clamp. 8) Remove circlip (1) by using special tool. Special tool (B): 0990006107 9) Remove magnet clutch coil (2) from compressor (3).
(B) 2
I4RS0A720044-

7) Tighten armature plate bolt to specified torque. Tightening torque Armature plate bolt (a): 15 Nm (1.5 kg-m, 11.0 lb-ft)
1

Special tool (A): 0999106310

I4RS0A720042-

Air Conditioning System:

7B-32

Relief Valve Inspection

S4RS0A7206031

(a)

By using special tool, check if there is refrigerant leakage. If there is refrigerant leakage, replace the relief valve. Special tool (A): 0999086011
(A)

I4RS0A720045-

8) Adjust clearance between magnet clutch plate (1) and magnet clutch pulley by putting shim(s) on compressor shaft. To measure the clearance, perform the following steps. a) Put compressor in a vise (2). b) Set dial gauge (3) on magnet clutch plate, and then adjust its pointer at 0. c) Connect battery positive terminal (+) to magnet clutch coil lead wire. d) Connect battery negative terminal () to compressor body assembly. (At this point, magnet clutch plate and magnet clutch pulley are kept in contact.) e) Disconnect battery negative terminal () to compressor body assembly. (At this point, magnet clutch plate and magnet clutch pulley are not in contact.) f) Read stroke of magnet clutch plate from dial gauge by performing step d) and e) repeatedly. (Stroke of magnet clutch plate is clearance between magnet clutch plate and magnet clutch pulley.) Standard clearance between magnet clutch plate and magnet clutch plate: 0.3 0.5 mm (0.012 0.020 in.)

I4RS0A720047-

Relief Valve Removal and Installation

S4RS0A7206038

Removal 1) Recover refrigerant from the A/C system with recovery and recycling equipment referring to Recovery in Operation Procedure for Refrigerant Charge: . 2) Remove relief valve (1) from compressor (2).
2

1
I4RS0A720048-

I4RS0A720046-

7B-33 Air Conditioning System: Installation Reverse removal procedure noting the following instructions. Use new O-ring. Apply compressor oil to O-ring. Tighten relive valve to the specified torque. Tightening torque Relief valve (a): 8 Nm (0.8 kg-m, 6.0 lb-ft)

(a)
I4RS0A720049-

Evacuate and charge the A/C system referring to Evacuation and Charge in Operation Procedure for Refrigerant Charge: .

Specifications
Tightening Torque Specifications
S4RS0A7207001

Fastening part Cap A/C refrigerant pressure sensor Armature plate bolt Relief valve NOTE:

N m 3.0 11 15 8

Tightening torque kg-m 0.3 1.1 1.5 0.8

lb-ft 2.5 8.0 11.0 6.0

Note

The specified tightening torque is also described in the following. Compressor Assembly Components: Reference: For the tightening torque of fastener not specified in this section, refer to Fasteners Information: in Section 0A.

Air Conditioning System:

7B-34

Special Tools and Equipment

Recommended Service Material
S4RS0A7208001

Material Compressor oil NOTE:

SUZUKI recommended product or Specification Compressor oil P/No.: 9900099015 (MATSUSHITADENKI) - Domestic 00A

Note

Required service material is also described in the following. Precautions on Servicing A/C System:

Special Tool
S4RS0A7208002

0990006107 Snap ring pliers (opening type) ///

0999086011 Gas leak detector /

0999106310 Armature plate holder /

7B-35 Air Conditioning System: